U.S. patent number 7,641,028 [Application Number 11/612,911] was granted by the patent office on 2010-01-05 for integrated and self-contained suspension assembly having an on-the-fly adjustable air spring.
This patent grant is currently assigned to Fox Factory, Inc.. Invention is credited to Robert C. Fox.
United States Patent |
7,641,028 |
Fox |
January 5, 2010 |
**Please see images for:
( Certificate of Correction ) ** |
Integrated and self-contained suspension assembly having an
on-the-fly adjustable air spring
Abstract
An integrated and self-contained suspension assembly having a
gas spring integrated with a shock absorber (damper) is described.
The rigid gas cylinder of the air spring is divided into a first
gas chamber and a second gas chamber. A flow port connects the
first and second gas chambers, and can be manually opened or closed
by valve and a simple one-quarter turn rotation of an external knob
to instantly switch the gas spring between two different spring
rates. The different spring rates are functions of the separate or
combined volumes of the two gas chambers. The integrated suspension
assembly is compactly packaged and self-contained, i.e., does not
require any externalities, such as gas sources or electricity, to
operate.
Inventors: |
Fox; Robert C. (Los Gatos,
CA) |
Assignee: |
Fox Factory, Inc. (Watsonville,
CA)
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Family
ID: |
29740716 |
Appl.
No.: |
11/612,911 |
Filed: |
December 19, 2006 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20080179795 A1 |
Jul 31, 2008 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10237333 |
Sep 5, 2002 |
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60392802 |
Jun 28, 2002 |
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60391991 |
Jun 25, 2002 |
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Current U.S.
Class: |
188/299.1;
267/64.28; 188/322.13; 188/278 |
Current CPC
Class: |
F16F
13/002 (20130101); F16F 9/0209 (20130101); B60G
15/12 (20130101); F16F 9/46 (20130101); B62K
25/04 (20130101); F16F 9/06 (20130101); B60G
17/0523 (20130101); F16F 9/0236 (20130101); F16F
9/461 (20130101); B62K 2025/048 (20130101); F16F
9/3257 (20130101); B62K 2201/08 (20130101); B60G
2300/12 (20130101); F16F 2228/066 (20130101); B60G
2500/20 (20130101) |
Current International
Class: |
F16F
9/34 (20060101) |
Field of
Search: |
;188/278,322.13,322.14,322.2,299.1 ;267/64.11,64.26,64.28 |
References Cited
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WO |
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Other References
Fox document various articles--Motocross Action Dec 1981; Fox
Factory 1983; Moto-X Fox 1981; Vanilla Float 1998; Mountain Biking
Oct 1998; Cycle World Dec 1981; undated. cited by other .
Cerian 1 various articles undated. cited by other .
Mountain Bike Action--various articles dated Feb. 1992, Jan. 1993,
Nov. 1991, Jan. 1993, Dec. 1997 and Feb. 1991. cited by other .
Bicycling Aug. 1993. cited by other .
Mountain Biking Oct. 1996. cited by other .
Bike Pulse May 2000. cited by other .
Road Bike Aug. 1993. cited by other .
Mountain Bike Aug. 2001. cited by other .
Collection of Rock Shox Documents--various articles dated 1993,
1996-1998, 2000, 2004. cited by other .
Cannondale Documents--various articles dated 1993 and undated.
cited by other .
Marzocchi literature undated. cited by other .
Bicycle Guide Jul. 1994. cited by other .
Various Articles: Maverick American, Paul Turner, Profile. cited by
other .
Sospensioni Jan. 1993. cited by other .
Mountain Tutto Bike Sep. 1992. cited by other .
Bici Da Montagna Mar. 1994. cited by other .
Listing of Forks undated, unidentified, 1987-1991. cited by
other.
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Primary Examiner: Nguyen; Xuan Lan
Attorney, Agent or Firm: Patterson & Sheridan, L.L.P.
Haugen; David M.
Claims
That which is claimed:
1. An integrated and self-contained suspension unit for a vehicle
comprising: a gas spring unit comprising a rigid gas cylinder
having at least one open end and an inner surface; a damper
assembly comprising: a damping cylinder containing damping fluid
and having a damping rate, the damping cylinder having first and
second damping cylinder ends, wherein the first end of the damping
fluid cylinder is telescopically housed within the gas cylinder; a
seal head, the seal head at least partially associated with the
damping cylinder; a sliding seal secured to an outer portion of the
seal head and slidably engageable with the inner surface of the gas
cylinder and creating a variable-volume sealed gas chamber within
the gas cylinder; a quantity of gas contained within the sealed gas
chamber; a partition within the gas cylinder and dividing the gas
chamber into a first gas chamber and a second gas chamber; a flow
port within the gas cylinder and capable of providing gas flow
communication from the first gas chamber to the second gas chamber;
an externally-adjustable valve mechanism associated with the flow
port and having at least an open position and a closed position,
wherein in the closed position gas flow communication from the
first gas chamber to the second gas chamber is prevented; a manual
adjuster located on an exterior portion of the integrated
suspension unit, the adjuster permitting selective manual
adjustment of the valve mechanism between the open position and the
closed position in an on-the-fly manner during operation of the
vehicle; wherein: a) when the valve mechanism is in the open
position, the first and second gas chambers are in gas flow
communication and contribute to a first discrete gas spring rate
that is a function of at least the combined volume of the first and
second gas chambers; and b) when the valve mechanism is in the
closed position and the pressure in the second gas chamber does not
exceed a predetermined value, the first and second gas chambers are
not in gas flow communication and contribute to a second discrete
gas spring rate that is not a function of the volume of the second
chamber; a first eyelet for attaching the integrated and
self-contained suspension assembly to one of the sprung or
un-sprung masses of the two-wheeled vehicle; and a second eyelet
for attaching the integrated and self-contained suspension assembly
to the other of the sprung or un-sprung masses of the two-wheeled
vehicle; and wherein substantially the entire integrated and
self-contained suspension assembly is positioned between the first
and second eyelets.
2. The integrated and self-contained suspension assembly of claim
1, wherein: the valve mechanism includes a check valve positioned
between the first and second chambers and biased towards the closed
position by a sealing force; and when the gas pressure in the
second gas chamber exceeds the sum of the gas pressure in the first
gas chamber and the sealing force of the check valve, the check
valve allows gas flow.
3. The integrated and self-contained suspension assembly of claim
1, wherein: a) the first discrete spring rate results in the gas
pressure in the gas spring reaching a specified value during a
first travel distance of the suspension assembly; b) the second
discrete spring rate results in the gas pressure in the gas spring
reaching the specified value during a second travel distance of the
suspension assembly; and c) the first travel distance is greater
than the second travel distance.
4. The integrated and self-contained suspension assembly of claim
1, wherein the damper assembly further comprises: a damper shaft; a
damping adjuster rod capable of controlling the damping rates and
located inside the damper shaft.
5. The integrated and self-contained suspension assembly of claim
1, wherein: the gas spring is divided into separate positive and
negative gas springs; and the first and second gas chambers form
the positive gas spring.
6. The integrated and self-contained suspension assembly of claim
1, wherein the damper assembly further comprises: a damping piston
having at least one orifice there through; a damper shaft; the
damper shaft having a first end protruding from an end of the
damping cylinder and extending into the gas cylinder and a second
end supporting the damping piston; and the damping rate of the
damper assembly portion of the integrated and self-contained
suspension unit being a function of the degree of resistance to
damping fluid flow through the at least one orifice.
7. An integrated and self-contained suspension unit for a
two-wheeled vehicle comprising a gas spring unit including a rigid
gas cylinder having at least one open end and an inner surface; a
damper assembly including: a damping cylinder containing damping
fluid and having a damping rate, the damping cylinder having first
and second damping cylinder ends, wherein the first end of the
damping fluid cylinder is telescopically housed within the gas
cylinder; a damper shaft; and a damping adjuster rod cable of
controlling the damping rate and located inside the damper shaft; a
seal head, the seal head at least partially associated with the
damping cylinder; a sliding seal secured to an outer portion of the
seal head and slidably engageable with the inner surface of the gas
cylinder and creating a variable-volume sealed first gas chamber
within the gas cylinder; a quantity of gas contained within the
sealed gas chamber; a second gas chamber in gas flow communication
with the first gas chamber; a flow port for controlling gas flow
communication from the first gas chamber to the second gas chamber;
an externally-adjustable valve mechanism associated with the flow
port and having at least an open position and a closed position,
wherein in the closed position gas flow communication from the
first gas chamber to the second gas chamber is prevented; a manual
adjuster located on an exterior portion of the integrated
suspension unit, the adjuster permitting selective manual
adjustment of the valve mechanism between the open position and the
closed position in an on-the-fly manner during operation of the
two-wheeled vehicle; and wherein: a) when the valve mechanism is in
the open position, the first and second gas chambers are in gas
flow communication and contribute to a first discrete gas spring
rate that is a function of at least the combined volume of the
first and second gas chambers; and b) when the valve mechanism is
in the closed position, the first and second gas chambers are not
in gas flow communication and contribute to a second discrete gas
spring rate that is not a function of the volume of the second
chamber.
8. The integrated and self-contained suspension assembly of claim
7, wherein: a) the first discrete spring rate results in the gas
pressure in the gas spring reaching a specified value during a
first travel distance of the suspension assembly; b) the second
discrete spring rate results in the gas pressure in the gas spring
reaching the specified value during a second travel distance of the
suspension assembly; and c) the first travel distance is greater
than the second travel distance.
9. An integrated and self-contained suspension unit for a vehicle
comprising: a gas spring unit comprising a rigid gas cylinder
having at least one open end and an inner surface; a damper
assembly comprising: a damping cylinder containing damping fluid
and having a damping rate, the damping cylinder having first and
second damping cylinder ends, wherein the first end of the damping
fluid cylinder is telescopically housed within the gas cylinder; a
damper shaft; and a damping adjuster rod capable of controlling the
damping rate and located inside the damper shaft; a seal head, the
seal head at least partially associated with the damping cylinder;
a sliding seal secured to an outer portion of the seal head and
slidably engageable with the inner surface of the gas cylinder and
creating a variable-volume sealed gas chamber within the gas
cylinder; a quantity of gas contained within the sealed gas
chamber; a partition within the gas cylinder and dividing the gas
chamber into a first gas chamber and a second gas chamber; a flow
port within the gas cylinder and capable of providing gas flow
communication from the first gas chamber to the second gas chamber;
an externally-adjustable valve mechanism associated with the flow
port and having at least an open position and a closed position,
wherein in the closed position gas flow communication from the
first gas chamber to the second gas chamber is prevented; a manual
adjuster located on an exterior portion of the integrated
suspension unit, the adjuster permitting selective manual
adjustment of the valve mechanism between the open position and the
closed position in an on-the-fly manner during operation of the
vehicle; wherein: a) when the valve mechanism is in the open
position, the first and second gas chambers are in gas flow
communication and contribute to a first discrete gas spring rate
that is a function of at least the combined volume of the first and
second gas chambers; and b) when the valve mechanism is in the
closed position and the pressure in the second gas chamber does not
exceed a predetermined value, the first and second gas chambers are
not in gas flow communication and contribute to a second discrete
gas spring rate that is not a function of the volume of the second
chamber.
10. An integrated and self-contained suspension unit for a vehicle
comprising: a gas spring unit comprising a rigid gas cylinder
having at least one open end and an inner surface; a damper
assembly comprising: a damping cylinder containing damping fluid
and having a damping rate, the damping cylinder having first and
second damping cylinder ends, wherein the first end of the damping
fluid cylinder is telescopically housed within the gas cylinder; a
damping piston having at least one orifice there through; a damper
shaft having a first end protruding from an end of the damping
cylinder and extending into the gas cylinder and a second end
supporting the damping piston; and the damping rate of the damper
assembly portion of the integrated and self-contained suspension
unit being a function of the degree of resistance to damping fluid
flow through the at least one orifice a seal head, the seal head at
least partially associated with the damping cylinder; a sliding
seal secured to an outer portion of the seal head and slidably
engageable with the inner surface of the gas cylinder and creating
a variable-volume sealed gas chamber within the gas cylinder; a
quantity of gas contained within the sealed gas chamber; a
partition within the gas cylinder and dividing the gas chamber into
a first gas chamber and a second gas chamber a flow port within the
gas cylinder and capable of providing gas flow communication from
the first gas chamber to the second gas chamber; an
externally-adjustable valve mechanism associated with the flow port
and having at least an open position and a closed position, wherein
in the closed position gas flow communication from the first gas
chamber to the second gas chamber is prevented; a manual adjuster
located on an exterior portion of the integrated suspension unit,
the adjuster permitting selective manual adjustment of the valve
mechanism between the open position and the closed position in an
on-the-fly manner during operation of the vehicle; wherein: a) when
the valve mechanism is in the open position, the first and second
gas chambers are in gas flow communication and contribute to a
first discrete gas spring rate that is a function of at least the
combined volume of the first and second gas chambers; and b) when
the valve mechanism is in the closed position and the pressure in
the second gas chamber does not exceed a predetermined value, the
first and second gas chambers are not in gas flow communication and
contribute to a second discrete gas spring rate that is not a
function of the volume of the second chamber.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
A preferred embodiment relates to air springs for vehicle
suspensions and preferably two-wheeled vehicle suspensions, such as
the suspensions of bicycles, which are typically mounted between
the chassis of the vehicle and a wheel. In particular, a preferred
embodiment relates to an air spring, optionally combined with a
shock absorber or other damper to form an integrated suspension
unit, which permits instant selection between two different spring
rate curves by simply rotating an external knob one-quarter
turn.
2. Description of the Related Art
One advantage of air springs is the ability to change spring rate
("softer" or "stiffer") simply by adjusting the internal air
pressure. Such a method permits changing the spring rate curve of
an air spring, and is available for essentially all air springs. On
many air springs this is accomplished relatively easily by
pressurizing or de-pressurizing the air spring with a hand pump and
gauge, or by using an air pressure hose at an automobile service
station ("gas station"). Most air springs are purposely designed
with a standardized Schrader air valve (similar to those in
automobile tires) to make this relatively easy and convenient.
As is known in the art, spring rate characteristics can also be
changed by altering the initial air chamber volume. Increasing or
decreasing initial air chamber volume softens or stiffens,
respectively, the air spring curve.
Conventional prior-art air springs for bicycles and motorcycles
have been known to provide features for altering air chamber
volume. The most common method, used especially in air-sprung
mountain bike front forks, is to increase or decrease air chamber
volume by adding or removing hydraulic fluid ("changing the oil
level"). In other cases, air spring suspension components have been
provided with solid, light-weight, "volume plugs". The air spring
is opened and the "volume plugs" are added or removed from the air
chamber. Both methods, of course, generally require
depressurization and opening of the hydraulic unit and/or the air
spring.
Another feature known in the art for altering the air chamber
volume on certain bicycle and motorcycle air springs has been an
adjustable-position threaded cap closing off the air chamber.
Threading this cap in or out, which can require a fair amount of
torque to overcome frictional forces resulting from the internal
pressure, changes the air chamber volume. For example, U.S. Pat.
No. 5,346,236 teaches this for a bicycle front fork. Also known in
the art is a threaded-cap adjustable-volume external air reservoir
which can be added to a basic shock absorber or fork air spring.
Changes of this type can typically be accomplished faster than
adding or removing hydraulic fluid, and may be accomplished in
about 1 minute.
Motorcycles having air suspension with an on-board pressurization
system including an on-board air compressor to monitor and regulate
air pressure on demand, are also known in the art.
There is a need in bicycles and motorcycles which incorporate air
spring suspension for a quick, easy way to alter the air spring
curve "on-the-fly". All the prior-art methods noted above suffer
from various limitations, including time and effort required,
weight, bulk, complexity, and cost.
SUMMARY OF THE INVENTION
One aspect of a preferred embodiment is to provide a suspension air
spring, optionally integrated with a shock absorber or other
damper, that permits instant selection between "soft" and "firm"
spring rate curves by simply turning an external knob one-quarter
turn. This is much quicker and easier than other methods provided
by conventional prior-art designs. The illustrated embodiments are
particularly applicable to bicycles.
In the context of real-world mountain biking, all prior-art methods
of changing air spring rates create a significant interruption in
the ride, and thus typically are done infrequently, or not at all,
during a ride. In contrast, turning an external knob as described
according to a preferred embodiment is so quick and simple that it
can be done in a routine "on-the-fly" manner dozens of times as
desired during a typical ride. Since terrain and trail conditions
constantly change, this greatly benefits the rider by enabling
him/her to continuously select the best spring rate for the current
situation.
The illustrated embodiments achieve this result by partitioning the
air spring (more generally, "gas spring") into two separate partial
volumes. The two partial volumes are connected by a sealed passage
which is selectively opened or closed by turning an external knob.
Turning the knob rotates a cam which desirably is in contact with a
cam follower. The cam follower then preferably moves a check ball
up or down, causing the ball to either seat on or unseat from,
respectively, a seal in the connecting passage
When the check ball is seated, the passage is closed and air flow
from the first partial volume to the second partial volume is
blocked. This isolates the second partial volume and prevents it
from physically participating as a part of the air spring upon
compression of the suspension. As is well-known in the art, air
spring characteristics depend upon the initial pressure and volume
characteristics of the air spring. When the total initial volume is
effectively reduced, as occurs here when the passage leading to the
second partial volume is blocked, the air spring characteristic
("spring curve") becomes firmer.
When the check ball is unseated, the passage is open and air flow
between the two partial volumes is unrestricted. This, of course,
makes both partial volumes physically available to the air spring,
and results in greater total initial volume and a softer air spring
characteristic.
A preferred embodiment is an air spring for a two wheeled vehicle.
The air spring being positionable between a vehicle sprung mass and
a vehicle wheel. The air spring includes an air cylinder closed at
one end and connectable to one of a vehicle sprung mass and a
vehicle wheel. A piston is in axially-slidable engagement with the
air cylinder and is connectable to the other of a vehicle sprung
mass and a vehicle wheel. A partitioning member is positioned
within the cylinder and at least partially divides the cylinder
into a primary air chamber and a secondary air chamber. A passage
connects the primary air chamber and the secondary air chamber and
a valve assembly is configured to selectively permit air flow
through the passage.
Another preferred embodiment is a gas spring assembly including a
body portion and a shaft portion. The shaft portion is
telescopingly engaged with the body portion. A piston is carried by
the shaft portion and cooperates with the body portion to define a
variable volume first gas chamber. One of the shaft portion and the
body portion at least partially defines a second gas chamber. A
valve assembly is positionable in a first position and a second
position. In the first position, the valve assembly substantially
prevents communication between the first gas chamber and the second
gas chamber and in the second position, the valve assembly permits
communication between the first gas chamber and the second gas
chamber.
Another aspect of the present invention involves a front suspension
fork assembly positionable on a bicycle. The front fork assembly
includes a gas spring assembly having a body portion and a shaft
portion. The shaft portion is telescopingly engaged with the body
portion. A piston is carried by the shaft portion and cooperates
with the body portion to define a variable volume first gas
chamber. One of the shaft portion and the body portion at least
partially defines a second gas chamber. A valve assembly is
positionable in a first position and a second position. In the
first position, the valve assembly substantially prevents
communication between the first gas chamber and the second gas
chamber and in the second position, the valve assembly permits
communication between the first gas chamber and the second gas
chamber. The valve assembly is movable between the first position
and the second position by an actuator positioned to be accessible
to a hand of a rider of the bicycle while riding.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall front view of a prior-art embodiment of a
suspension unit consisting of a shock absorber ("damper")
integrated with an air spring.
FIG. 2 is a partial sectional front view of the prior-art
suspension unit of FIG. 1.
FIG. 3 illustrates the effect of the negative chamber by comparing
the spring curve of the prior-art suspension unit of FIG. 2 with
the spring curve it would have if the negative chamber was
eliminated.
FIG. 4 is an overall front view of a preferred embodiment of a
suspension unit.
FIG. 5 is an overall side view of the suspension unit of FIG.
4.
FIG. 6 is a partial sectional front view of the suspension unit of
FIG. 4.
FIG. 7 is a partial sectional top view of the suspension unit of
FIG. 6.
FIG. 8 is an enlarged partial sectional view of the suspension unit
of FIG. 6.
FIG. 9 is an isometric view of the upper eyelet housing of the
suspension unit of FIG. 6.
FIG. 10 is an isometric view of the air sleeve partition of the
suspension unit of FIG. 6.
FIG. 11 is an enlarged partial sectional view of the switching
mechanism of the suspension unit of FIG. 6, with the adjusting
lever set so the air passage is open.
FIG. 12 is an enlarged partial sectional view of the switching
mechanism of the suspension unit of FIG. 6, with the adjusting
lever set so the air passage is closed.
FIG. 13 is a partial sectional view of the suspension unit of FIG.
6, showing the approximate full travel position with the adjusting
lever set in the open position.
FIG. 14 is a partial sectional view of the suspension unit of FIG.
6, showing the approximate full travel position with the adjusting
lever set in the closed position.
FIG. 15 illustrates the effect of the lever adjustment by comparing
the spring curves of the suspension unit of FIG. 6 with the lever
in the closed position, and with it in the open position.
FIG. 16 shows an alternate embodiment of a suspension unit, where
the connecting passageway occurs through the center shaft.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The prior-art integrated suspension unit 100 of FIGS. 1 and 2 will
be described first, in order to provide a point of departure for
better understanding the improvements of the preferred embodiments,
which will be described further on.
The typical prior-art integrated suspension unit 100 as shown in
FIGS. 1 and 2 is manufactured by Fox Racing Shox. It is to be
understood, of course, that this specific prior-art embodiment is
representative only, and that the present air spring arrangement
can be applied to other types of suspension units. Additionally,
the present air spring arrangement can be applied as a separate air
spring unit, not integrated with a damper.
In FIGS. 1 and 2 the integrated suspension unit 100 is comprised of
an air spring assembly 110 and a damper assembly 190. The
integration is seamless, with several of the components such as an
upper eyelet housing 116 and seal head 194 shared by both
assemblies and performing dual functional roles. For example, as
part of the damper assembly 190, the seal head 194 closes and seals
off one end of the shock body 197. At the same time, as part of the
air spring assembly 110, the seal head 194 also seals off the open
end of the air cylinder 126 and functions as a piston of the air
spring assembly 110. The air cylinder 126 functions as a body
portion of the air spring assembly 10 and the shock body 197
functions as a shaft portion of the air spring assembly 110.
Still referring to FIGS. 1 and 2, the ends of the integrated
suspension unit 100, the upper eyelet 114 and the lower eyelet 198,
are connected to the sprung and unsprung portions of the vehicle
(not shown) in a conventional manner. The air pressure in the
positive air chamber 128 creates a force tending to lengthen the
suspension unit 100, while pressure in the negative air chamber 136
tends to shorten it. As is well-known in the art, the net effect of
these opposing forces is to create a desirable air spring curve
("force vs. travel curve"), especially in that portion of the
travel regime where the suspension unit 100 is near full
extension.
In particular, it is well-known that without the counteracting
force produced by the negative air chamber 136, which rapidly
increases as the shock absorber approaches full extension and the
volume of the negative air chamber 136 rapidly decreases, the
initial portion of the spring curve ("spring preload") would be
quite stiff. Thus, an undesirably large beginning force would be
required to initiate the first portion of travel from full
extension.
Typical spring curves produced with and without the negative air
chamber 136 are illustrated in FIG. 3. Curve "A" shows a force
versus travel spring curve that would be produced by the embodiment
of FIG. 2, which includes the negative air chamber 136. In
contrast, Curve "B" shows the spring curve that would result if the
negative air chamber 136 was removed (not shown). On a bicycle, or
other vehicle, spring curve "B" would generally produce an
undesirably harsh ride due to the large initial force required to
initiate travel from full extension.
The positive air chamber 128 is pressurized via the air valve 112.
As is typical, an air passage (not shown) is drilled in the upper
eyelet housing 116, and leads from the air valve 112 to the
positive air chamber 128.
The negative air chamber 136 is pressurized via a transfer port
132. Transfer occurs at that pre-determined point near the
beginning of suspension travel where the transfer port 132 bridges
the positive/negative seal assembly 130, as depicted in FIG. 2.
This air transfer feature provides an effective and simple means
for properly balancing the pressures of the positive air chamber
128 and the negative air chamber 136, and is more fully described
in U.S. Pat. No. 6,135,434.
The positive/negative seal assembly 130 provides a moving seal
between the positive air chamber and the negative air chamber and
seals at all times except when bridged by the transfer port 132.
The inside bore of the air cylinder 126 is burnished or otherwise
finished to provide a smooth, low-friction surface which seals
well.
The negative chamber seal assembly 140 seals the lower side of the
negative chamber on the outside of the shock body 197, which is
burnished or otherwise finished to provide a smooth, low-friction
surface which seals well.
The prior-art integrated suspension unit 100 of FIGS. 1 and 2
includes provisions for adjusting the internal damping by rotating
a damping adjuster knob 191 which, in turn, rotates the damping
adjuster rod 192 which extends down the shaft 193 into the piston
assembly 195. This basic construction, available in many
conventional high-performance shock absorbers and well-known to
those skilled in the art, enables external adjustability of
compression damping, rebound damping, or both.
Although this damper construction feature is not required for
application of the preferred embodiments, it is illustrated here in
the prior-art and it is also included in the illustrated embodiment
shown in FIG. 6. If this adjustable damping feature is not
included, a somewhat simplified and less costly preferred
embodiment, as described later and illustrated in FIG. 16, is made
possible.
The rest of the prior-art integrated suspension unit 100, including
the piston assembly 195 of the damper assembly 190 which creates
damping as it moves thru the damping fluid 196, are not illustrated
or described in further detail since they are conventional features
well-known to those skilled in the art, and are not required for an
understanding of the preferred embodiments.
External views of a preferred embodiment are shown in FIGS. 4 and
5. Suspension unit 200 comprises a damper assembly 190 identical to
that of FIG. 1, and an adjustable air spring assembly 210. A
manually-operable travel adjust lever 252 extends from the upper
portion of suspension unit 200. The travel adjust lever 252 can be
rotated 90-degrees clockwise or counterclockwise between the two
positions shown, the "long-travel mode" and the "short-travel
mode", as will be described more fully further on.
FIG. 6 shows a partial sectional view of the suspension unit 200 of
FIG. 4. In comparison to the prior-art device of FIGS. 1 and 2, the
damper assembly 190 of FIG. 6 is identical to the damper assembly
190 of FIGS. 1 and 2; however, the adjustable air spring assembly
210 of FIG. 6 contains additional structure and modified structure
as compared with air spring assembly 110 of FIGS. 1 and 2. The
additional and modified structure comprises an air cylinder
partition 272 sealed within the air cylinder 126 which separates
the divided positive air chamber 228 into a first partial volume
227 and a second partial volume 229, and a travel adjust assembly
250 which enables these two partial volumes to be either connected
or separated by rotation of the external travel adjust lever
252.
FIGS. 7 and 8 show enlarged views illustrating this additional
structure and modified structure, which will now be described in
detail. In FIG. 8 and other drawings, various seals (such as a
conventional O-ring seal between the air cylinder 126 and the air
cylinder partition 272) are included in the drawing, but are not
numbered or described, since they are conventional features
well-known to those skilled in the art.
The detent ball assembly 260 provides a detenting effect such that,
after adjustment, the travel adjust lever 252 is held in the
selected position. It also provides tactile feedback to the
operator to indicate attainment of a new position upon rotation.
The travel adjust lever 252 is incorporated into the upper eyelet
housing 216 and is secured to an actuating cam shaft 254 by a
retaining screw 256. A surface of the actuating cam shaft 254 has a
ball indent 255 spaced every 90-degrees on its outer surface near
one end. A surface of a detent ball 262, urged by a detent spring
264 which is secured by a detent set screw 266, engages the ball
indent 255. Thus, in an engaged position, the detent ball 262
engages one of the ball indents 255 and a first level of resistance
to rotation of the travel adjust lever 252 is provided that,
desirably, inhibits unintentional rotation of the lever 252, while
still allowing the lever 252 to be rotated by hand. In an unengaged
position, the detent ball 262 contacts a surface of the cam shaft
254 between the indents 255 and, desirably, provides little or no
resistance to rotation of the travel adjust lever 252.
In FIG. 8, the retaining ring 278 serves to secure the axial
location of the air cylinder partition 272 on the shaft 193.
In order to facilitate clear visualization of the interface between
the upper eyelet housing 216 and the air cylinder partition 272,
FIG. 9 shows an isometric view of the upper eyelet housing 216, and
FIG. 10 shows an isometric view of the air cylinder partition 272.
As shown, the underside of the upper eyelet housing 216 includes a
downwardly-projecting upper passage port coupler 217 which engages
the upwardly-projecting lower passage port boss 273 thru which the
lower passage port 274 passes. This connection is sealed by a lower
passage port seal 276 as shown in FIG. 11. In addition, the upper
eyelet housing 216 includes an upper passage port 219, which
preferably extends completely through the upper passage port
coupler 217, in a direction perpendicular to a longitudinal axis
thereof, as shown in FIG. 11.
FIG. 11 shows an enlarged partial sectional view of the travel
adjust assembly 250, which is now described in detail. As
previously described, the travel adjust lever 252 is secured to the
actuating cam shaft 254 by a retaining screw 256. The actuating cam
shaft 254 is retained in the upper eyelet housing 216 by a
retaining screw 253. The actuating cam shaft 254 includes a cam
profile 259. This cam profile 259 consists of 2 flats 259A
180-degrees apart as shown here in FIG. 11, and 2 deeper flats 259B
as shown in FIG. 12, which also are 180-degrees apart and are at
90-degrees from flats 259A. These flats control the position of the
cam follower 258, as determined by the setting of the travel adjust
lever 252. Cam follower 258 is sealed by cam follower seal 257.
With the travel adjust lever 252 in the position shown in FIG. 11,
the cam follower 258 is in contact with the check ball 282 and
maintains it in a position out of contact with the check ball seal
283. As shown by the heavy flow lines drawn, this enables air flow
from the first partial volume 227 (not shown in this view) thru the
lower passage port 274, past the check ball 282, thru the upper
passage port 219, and into the second partial volume 229 (not shown
in this view). This is one direction of air flow. The opposite
direction of air flow is also enabled. These flows, of course,
provide open communication between the first partial volume 227 and
the second partial volume 229 such that their combined volume is
available during compression of the suspension unit 200.
FIG. 12 shows the travel adjust lever 252 in the closed position.
The cam follower 258, urged upward by internal air pressure,
engages cam profile 259B and, as shown, moves away from check ball
282 by a distance "X", which is desirably 0.040'' or more. The
check ball 282, urged upward by the check ball spring 284 engages
check ball seal 283. This seals off any upward air flow from first
partial volume 227 to second partial volume 229.
However, this does not seal off flow in the opposite direction,
since check ball spring 284 is specified to produce only a small
spring force, for example about 0.03 to 0.05 pounds, with the check
ball 282 in the sealed position. Accordingly, if the pressure from
the second partial volume 229 above the check ball 282 exceeds the
pressure below it from first partial volume 227 by approximately 3
to 5 psi, then this pressure differential will overcome the force
of check ball spring 284 and check ball 282 will move downward away
from sealing contact with check ball seal 283. In this event, air
will flow from second partial volume 229 to first partial volume
227.
This characteristic is desirable in order to prevent unintended
entrapment of excess air and pressure in the second partial volume
229. For correct function of the adjustable air spring assembly
210, it is preferred that the pressure in second partial volume 229
does not become significantly greater than the pressure in first
partial volume 227. Such a situation would result in the pressure
within the first partial volume 227 being reduced from its initial,
preset level, due to the finite quantity of air within the
suspension unit 200. As a result, the spring rate of the air spring
200 in its short travel mode (i.e., only utilizing the first
partial volume 227) would be undesirably reduced from its initial
setting. Rather, according to the preferred embodiments, the
pressure in the second partial volume 229 preferably remains
approximately equal to or less than the pressure in first partial
volume 227, since the check ball spring 284 creates only a small
preload force.
Although the above-described valve assembly is preferred for its
simplicity, reliability and low manufacturing cost, other valve
arrangements may also be employed. For example, a needle-type valve
body may be used in place of the check ball 282. In an alternative
arrangement, the cam surface 259 may directly contact the valve
body (e.g., the check ball 282) and the cam follower 258 may be
omitted. Further, the above-described functions of the valve
assembly do not necessarily have to be performed by a single valve
arrangement. For example, a first valve arrangement may selectively
connect and disconnect the first partial volume 227 and second
partial volume 229, while another valve arrangement provides the
check valve function of preventing the pressure of the second
partial volume 229 from becoming substantially greater than the
pressure of the first partial volume 227.
FIG. 13 illustrates a typical full-travel position of suspension
unit 200 when travel adjust lever 252 is set in the long-travel
mode, such that first partial volume 227 and second partial volume
229 are in full communication.
Similarly, FIG. 14 illustrates a typical full-travel position of
suspension unit 200 when travel adjust lever 252 is set in the
short-travel mode, such that first partial volume 227 and second
partial volume 229 are in not in communication.
Note that the overall compressed lengths of suspension unit 200 are
different, with the length L.sub.1 in FIG. 13 being shorter than
the length L.sub.2 in FIG. 14. This will be explained with
reference to FIG. 15.
FIG. 15 illustrates an example of the force-versus-travel
relationships provided by suspension unit 200 in the two different
selectable modes: the short-travel mode and the long-travel mode.
In the long-travel mode, as shown by curve "B", the force rises
more gradually and reaches, in this example, a value of 750 pounds
at a stroke distance of about 1.75 inches. In the short-travel
mode, as shown by curve "A", the force rises more rapidly and
reaches a value of 750 pounds at a stroke distance of only about
1.27 inches, almost 1/2 inch less than the value for curve "B".
This relationship, of course, is the basis for describing the two
modes as "long-travel mode" and "short-travel mode".
It should be explained that, although for simplicity in the above
example a final external compression force of 750 pounds on the
suspension unit 200 is assumed for both cases, this is only an
approximation. A rigorous computer motion analysis of a specific
situation, centering on the basic equation of motion F=ma (force
equals mass times acceleration), would show some difference, but
this analysis is generally quite complicated and the difference
would generally be relatively small. Thus, the above is a
reasonably close approximation assuming that in both cases the
vehicle upon which the suspension unit 200 is mounted is subjected
to the same bump (or other terrain feature) and other
conditions.
Additionally, it should be noted that at 1.27 inches of travel
curve "A" is rising steeply. Thus, even if the final force that
occurs in the short-travel mode is somewhat greater than the 750
pounds used in the above example, final travel would still be
significantly less than curve "B". For example, even if the final
force reached 1000 pounds, final travel would still only be
slightly more than 1.40 inches. As a preferred embodiment of the
present invention is as a shock absorber for a mountain bike, it is
desirable that the final force is less than 3000 pounds, desirably,
less than 2000 pounds and, more desirably, less than 1000 pounds.
Such an arrangement allows the air spring to withstand the impact
forces resulting from traversing rough terrain with suspension
arrangements presently incorporated on mountain bikes (e.g., wheel
travel/shock travel ratio). As will be appreciated by one of skill
in the art, for other applications or suspension arrangements, the
preferred final force may vary from the values recited above.
In the context of mountain bike suspension assemblies, preferably,
the first partial volume 227 is between about 1 and 8 cubic inches.
Desirably, the first partial volume 227 is between about 1.5 and 6
cubic inches and, more desirably, between about 2 and 4 cubic
inches. Preferably, the second partial volume 229 is between about
0.3 and 4 cubic inches. Desirably, the second partial volume 229 is
between about 0.4 and 3 cubic inches and, more desirably, between
about 0.5 and 2 cubic inches. Such an arrangement provides a
desirable spring rate of the suspension unit 200 when utilizing
only the first partial volume 227, as well as when both the first
partial volume 227 and second partial volume 299 are used to
provide a spring force, for a substantial number of mountain bike
applications.
In at least a significant portion of mountain bike suspension
applications, it is preferable that the suspension unit 200
provides between about 0.5 and 3 inches of suspension travel in the
short travel mode (i.e., utilizing only the first partial volume
227). Desirably, the suspension unit 200 provides between about 0.6
and 2.5 inches of travel and, more desirably, between about 0.75
and 2 inches of suspension travel in the short travel mode.
Further, preferably the suspension unit provides between about 0.6
and 5 inches of suspension travel in the long travel mode (i.e.,
utilizing both the first partial volume 227 and the second partial
volume 229). Desirably, the suspension unit 200 provides between
about 0.8 and 4 inches of travel and, more desirably, between about
1 and 3 inches of suspension travel in the long travel mode. The
range of values set forth above pertains to the relative movement
between the two portions of the suspension unit 200 and the actual
travel of the suspended bicycle wheel may vary from the travel of
the suspension unit 200.
As described earlier, the differences between curve "A" and curve
"B" result from the differences in initial chamber volume available
during compression of the suspension unit 200. With the travel
adjust lever 252 set as in FIG. 13, the total volume of both the
first partial volume 227 and the second partial volume 229 are
available. With the travel adjust lever 252 set as in FIG. 14, only
the volume of first partial volume 227 is available.
These following example calculations will serve to clarify these
concepts.
These calculations are based on the well-known Ideal Gas Law for
isothermal processes, which is a good first approximation for
illustrating the basic principles of the preferred embodiments.
This law states that for an enclosed variable volume the internal
pressure will vary with volume according to the equation:
(P1)*(V1)=(P2)*(V2) where:
P1=initial gas (air) pressure
P2=second gas (air) pressure
V1=initial volume
V2=second volume
Here is a simple example of this relationship. Assuming the initial
conditions of a sealed, variable chamber are 10 cubic inches of air
at 100 psi, if the volume is then reduced to 5 cubic inches the
pressure will increase to 200 psi. Considered from another point of
view, initial volume divided by final volume equals "compression
ratio". In this example the compression ratio is 10 divided by 5,
or a compression ratio of 2. Final pressure can be calculated by
multiplying initial pressure times compression ratio: 100 psi times
2=200 psi.
In the example of FIGS. 13, 14, and 15, the initial first partial
volume 227 of suspension unit 200 is 3.08 cubic inches, and the
second partial volume 229 is 1.15 cubic inches. Thus, their
combined volume is 4.23 cubic inches, and the volume of first
partial volume 227 alone is just 3.08 cubic inches. For the
configuration of this example, volume displaced by the seal head
194 per inch of stroke is 1.65 cubic inches per inch. The following
sample calculations are made using these values:
For the configuration of FIG. 13, a compression ratio of 3.16 is
reached at 1.75 inches of travel:
initial total chamber volume=4.23 cubic inches
reduced volume at 1.75 inches travel=1.75.times.1.65=2.89 cubic
inches
chamber volume at 1.75 inches travel=4.23-2.89=1.34 cubic
inches
Thus:
compression ratio at 1.75 inches travel=(4.23)/(1.34)=3.16
For the configuration of FIG. 14, an almost identical compression
ratio of 3.14 is reached at 1.27 inches of travel:
initial total chamber volume=3.08 cubic inches
reduced volume at 1.27 inches travel=1.27.times.1.65=2.10 cubic
inches
chamber volume at 1.27 inches travel=3.08-2.10=0.98 cubic
inches
Thus:
compression ratio at 1.27 inches travel=(3.08)/(0.98)=3.14
For the configuration used in this example for suspension unit 200,
and assuming an initial pressure of 150 psi, these compression
ratios translate to an air spring force in both cases of about 750
pounds. However, the actual air spring force may vary depending on
the specific application. Preferably, as described above, in the
context of mountain bike suspension assemblies, the spring force is
less than approximately 3000 pounds at a substantially fully
compressed position of the air spring.
This example, of course, is by way of illustration only, and a wide
spectrum of desired relationships between compression ratio and
travel, and of the ratio of travel achieved in the short travel
mode with that achieved in the long travel mode, can be attained
with the illustrated embodiments by designing a particular variable
air spring with appropriate dimensional relationships. Preferably,
the percentage of travel achieved in the short travel mode with
that achieved in the long travel mode is between about 40 and 90
percent. Desirably, the percentage of travel achieved in the short
travel mode with that achieved in the long travel mode is between
about 50 and 85 percent and, more desirably, between about 60 and
80 percent. Such a change in travel provides desirable suspension
performance in both the short travel and long travel modes for at
least a significant portion of typical suspension arrangements
presently incorporated on mountain bikes.
FIG. 16 shows an alternate preferred embodiment. As discussed
previously, this embodiment is somewhat simplified and less costly
than the embodiment of FIG. 6. The embodiment of FIG. 16 is
possible for suspension units which are generally similar to that
of FIG. 6, but provided that no thru-shaft damping adjustment
feature, such as shown in FIG. 6, is required. As shown in FIG. 16,
when a thru-shaft damping adjustment feature is not required, then
the upper end of the shaft 393 becomes available for incorporation
of the travel adjust feature. Thus, the travel adjust valve in the
embodiment illustrated in FIG. 16 generally extends along a central
axis A of the shock shaft 393, which allows a simpler and more
cost-effective structure.
In this embodiment, the travel adjust assembly 350 uses the same
travel adjust lever 252 as utilized previously. The actuating cam
shaft 354 is similar to the previous actuating cam shaft 254, but
is somewhat longer. The upper eyelet housing 316 is similar to the
previous upper eyelet housing 216, but is somewhat simpler and less
costly to produce due to elimination of the previously-required
off-center upper passage port coupler 217 which was depicted in
FIG. 9. The air cylinder partition 372 is similar to the previous
air cylinder partition 272, but it also is somewhat simpler and
less costly to produce due in this case to elimination of the
previously-required off-center lower passage port boss 273 which
was depicted in FIG. 10. The lower passage port 374 and the upper
passage port 319, as shown, both consist of a cross-holes drilled
in the shaft 393. The upper passage port 319 further consists of
drilled or milled passageways in the lower portion of the upper
eyelet housing 316 which communicate with the drilled passageways
in the shaft 393.
The other elements of the travel adjust assembly 350 as shown in
FIG. 16 are neither numbered nor described here since they are
essentially identical to the elements numbered and described in the
embodiment of FIG. 6.
The present invention is not limited to the above embodiments and
various changes may be made within the technical scope of the
invention as understood by a person skilled in the art without
departing from the spirit and scope thereof.
* * * * *